Tub for wipes with resealable closure and printable back

ABSTRACT

A container for wipes includes a tub of thermoformed material. The tub comprises at least one side wall and a top integrally formed with the side wall. The container also includes a recess centrally located with respect to the top, and a first flange defined by the recess and including a first opening. The first flange is substantially parallel to the top. The container also includes a second opening defined by a periphery of the at least one side wall, and a second flange extending from the periphery of the at least one side wall.

RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 60/794,079, filed on Apr. 21, 2006.

BACKGROUND

Embodiments of the invention relate to packages for wipes, and particularly to a tub for wipes that includes a recess in its top to facilitate easy dispensing of wipes.

Cloths, towels, and similar items used for cleaning, drying, rubbing, bathing, and the like are often referred to as wipers or wipes. A variety of wipes are available in the market and their uses range from cosmetic and personal hygiene to industrial. Some wipes are dry while others are moistened with a cleanser, lotion, or other liquid (and sometimes referred to as “wet wipes”). Non-woven fabrics are often used for wipes and such wipes may take the form of and be packaged in accordance with, for example, the teachings of U.S. Pat. No. 6,164,441.

SUMMARY

Although, there are a variety of wipes and packages for such wipes, the packages are not always satisfactory. One problem that arises with wet wipes is that they tend to dry out after their package is opened. Thus, some mechanism must be provided for dispensing a limited number of wipes and thereafter resealing or reclosing the package so that additional wipes may be dispensed at a later time with minimal loss of moisture. Another problem with existing packages is that many of them are made from injection molded plastic. After their initial manufacture, such packages often must be printed upon or labeled in order to indicate the content of the packages. In addition, many packages are not designed in a manner that considers how the packaging itself may be used as an advertising mechanism. For example, if designed properly, it is possible for a package to act like a small billboard when presented on retail shelf space. Accordingly, there is a need for improved packages for wipes.

In one embodiment, the invention provides a container for wipes including a tub of thermoformed material. The tub comprises at least one side wall and a top integrally formed with the side wall. The container also includes a recess centrally located with respect to the top, and a first flange defined by the recess and including a first opening. The first flange is substantially parallel to the top. The container also includes a second opening defined by a periphery of the at least one side wall, and a second flange extending from the periphery of the at least one side wall.

In another embodiment, the invention provides a container operable to support wetted tissue material. The container includes a tub formed of thermoformed material. The tub has at least one side wall and a top integral to the at least one side wall. The container also includes a recess extending from the top, a first flange defined by the recess and including a first opening, and a periphery defining the first opening. The periphery has at least one substantially smooth edge portion and at least one toothed edge portion.

In another embodiment, the invention provides a method for forming a container to support a number of wipes. The method includes thermoforming a one-piece tub that has at least one side wall, a top integral with the side wall, a recess extending from the top, and a substantially flat surface defined within the recess. The method also includes forming a contour for a first opening on the substantially flat surface. Forming the contour includes the steps of defining at least one edge of a first flange, forming at least one substantially smooth cut portion, and forming at least one toothed cut portion.

Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exemplary tub for wipes.

FIG. 2 is a top view of an exemplary tub for wipes.

FIG. 3 is a cross-sectional view of an exemplary tub for wipes taken along the line 3-3 in FIG. 2.

FIG. 4 is an elevation view of an exemplary tub for wipes.

FIG. 5 is a cross-sectional view of an exemplary tub for wipes taken along the line 5-5 in FIG. 2.

FIG. 6 is a bottom perspective view of an exemplary tub for wipes including a backing.

FIG. 7 is a perspective view of another backing with an integral hang tag.

FIG. 8 is a perspective view of an exemplary tub for wipes including a label seal in a closed position.

FIG. 9 is a perspective view of an exemplary tub for wipes including the label seal in an open position.

FIG. 10 is a perspective view of an exemplary tub for wipes including toothed edge portions.

FIGS. 11 a-e are exemplary shapes of a first opening of an exemplary tub for wipes.

FIG. 12 is a perspective view of an exemplary tub for wipes with a square-like recess and a protrusion within the square-like recess.

FIG. 13 is a perspective view of an exemplary tub for wipes with a flat surface defined by the square-like recess.

FIG. 14 is a perspective view of an exemplary tub for wipes including a molded fitment in a closed position.

FIG. 15 is a perspective view of an exemplary tub for wipes including a molded fitment in an open position.

FIG. 16 is a top view of an exemplary tub for wipes including foot portions extending in a first direction.

FIG. 17 is a top view of an exemplary tub for wipes including foot portions extending in a second direction.

FIG. 18 is a top view of an exemplary tub for wipes aligned with an exemplary support.

FIG. 19 is a top view of an exemplary tub for wipes coupled to the exemplary support.

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.

FIGS. 1-6 illustrate a container or tub 10 having a first side wall 12, a second sidewall 14, a third sidewall 16, and a fourth sidewall 18. In the embodiment shown, the sidewalls 12, 14, 16, and 18 form one continuous wall. A top 22 is formed integral with the sidewalls 12, 14, 16, and 18. The top 22 lies generally within or near a horizontal plane P (FIGS. 1 and 4). The top 22 has a centrally positioned depression or recess 26. In other constructions, however, the recess 26 is located at other locations on the top 22 or in the side walls 12, 14, 16, 18. The recess 26 includes a flange 28 that is positioned below and substantially parallel to the top 22 of the tub 10. The flange 28 includes and inner edge 30 and defines a first opening 32 through which wipes, tissue towels, or similar products may be pulled. The tub 10 includes an open bottom or second opening 44 (FIGS. 3 and 5) located opposite to the top 22. The second opening 44 has a periphery 46. A bottom flange 48 extends outwardly from the periphery 46 of the second opening 44. In one embodiment, the flange 48 extends away from a central vertical axis A_(C) of the tub 10.

The tub 10 can be thermoformed or molded from a single piece or sheet of plastic or similar material. One advantage of forming the tub 10 in this manner is that prior to molding the tub 10, the sheet may be pre-printed or embedded with designs such as patterns, flowers, wood grain, or other graphics as well as with text or other indicia. This eliminates the need for later applied labels such as adhesive-backed paper labels, printing processes, and the like that are commonly applied to containers. If necessary, images may be printed or embedded in the plastic sheet in a pre-distorted manner that takes into account the stretching and movement that occurs when the flat sheet of plastic is molded three-dimensionally. In some embodiments, the tub 10 is molded with three-dimensional decorative features such as, for example, various designs, flowers, or any other features that are desired. Alternatively, the tub 10 may be vacuum formed or form-fill-sealed.

The flange 48 is configured to support a backing 52 (FIGS. 4 and 6) having a first side 54 and a second side 56. The backing 52 may be made from paper, card board (including coated paper or card board), plastic, plastic coated board, blister packing, or flexible film, and may be heat-sealed or induction sealed on the tub 10. Alternatively, the backing 52 may be fixed in place with an adhesive or by radio-frequency sealing. In some embodiments, the backing 52 is removable and/or resealable to allow reloading the tub 10 with wipes. With reference to FIG. 7, some constructions of the tub 10 include the backing 52 with an integral flap or hang tab 57 to provide a mechanism for supporting the tub 10 on retail display hooks. The hang tab 57 extends away from the tub 10 and may include a perforation 58 to facilitate its removal or tearing off by a consumer after the consumer purchases the product packaged in the tub 10. In one construction, the perforation 58 substantially matches the outer edge of the flange 48.

As noted, in some embodiments the backing 52 is made from a material that is different from the material from which the tub 10 is made. The backing 52 may be made from material that is readily printed upon such as paper or card board, blister packaging, or a flexible film material. The second side 56 of the backing 52 provides a convenient display area for labeling the tub 10 with the name of the contents, consumer instructions, drug facts, bar codes, RF tags, and other text and labeling content. A filled tub 10 may be positioned at retailers such that the information on the second side 56 is directed to the line of sight of consumers as they pass displays or shelves containing the tub 10. Thus, the backing 52 acts like a small billboard and provides space for manufacturers of the wipes to display informative and appealing content that consumers can readily read.

FIGS. 8 and 9 illustrate the opening 32 being sealed with one type of closure. More specifically, the closure referred to as a label seal 60 is be used to cover the recess 26. The label seal 60 includes a thin plastic or similar, substantially rigid sheet 61 that may be printed upon, a gripping portion 62, a sealing portion 63, a hinge portion 64, and two lateral portions 65. The hinge portion 64 and the lateral portions 65 of the label seal 60 may be permanently attached to the top 22, while the sealing portion 63 may be fixed to the top 22 with an adhesive capable of sealing the label seal 60 to the top 22 after multiple openings. Opening of the label seal 60 can be caused by a consumer gripping and pulling the gripping portion 62 of the label seal 60 from a closed position (FIG. 8) to an open position (FIG. 9). The label seal 60 has a tendency to go from the open position to the closed position (i.e., it exhibits memory) without interaction from the consumer, as illustrated by arrow 66 in FIG. 9.

As noted above, the flange 28 and opening 32 are located below the plane P. In addition, the label seal 60 is preferably configured to be positioned above the flange 28 (for example, substantially parallel with the top 22) leaving a gap between the label seal 60 and the flange 28 in which at least a part of the next wipe or paper tissue may be positioned. Thus, sufficient room is provided so that wipes may be folded in a manner where the removal of one wipe from the tub 10 through the opening 32 is accomplished and a part of the next wipe is pulled up from the opening 32 to be stored between the flange 28 and the label seal 60 in a position where it is readily grasped by a consumer.

FIG. 10 illustrates the opening 32 with the inner edge 30 including smooth edge portions 70 and toothed portions 72 interleaved with one another. Particularly, the inner edge 30 is defined by four smooth edge portions 70, each one being oriented towards the junction of one side wall 12, 14, 16, 18 and the top 22. The inner edge 30 is also defined by four toothed portions 72, each toothed portion 72 being substantially oriented towards the junction of two adjacent side walls 12, 14, 16, 18. In some embodiments, the inner edge 30 is one single smooth edge portion 70 and has no toothed portions 72. The number, length, and position of the toothed portions 72 can vary based on desired manufacturing specifications. Each of the toothed portions 72 illustrated in FIG. 10 includes a number of teeth, the size of which has been exaggerated for illustration purposes. As indicated above, wipes can be stored between the flange 28 and the label seal 60. The toothed portions 72 help support the wipe within the space between the flange 28 and the label seal 60 by gripping the wipe. The toothed portions 72 also help prevent the wipe from slipping or returning below the opening 32.

FIG. 11 a illustrates the shape of the opening 32 shown in FIGS. 1-2 and 8-10. FIGS. 11 b-11 e illustrate a number of alternate configurations of the opening 32. The shapes shown in FIGS. 11 a-11 e can be described as having two long-side edges 74, 76 and two short-side edges 78, 80. In the shapes illustrated in FIGS. 11 b and 11 e, the short-side edges 78 are more distinct and separately identifiable from the long-side edges 74 and 76. For example, the short-side edges 78, 80 in FIG. 11 b are characterized by having an elongated, oval shape whereas the short-side edges 78, 80 shown FIG. 11 a appear to be continuous with the long-side edges 74 and 76. The shape shown in FIG. 11 b is also defined by each short-side edge 78, 80 having two substantially parallel portions (78 a, 78 b, 80 a, and 80 b) joined by circular portions 81 and 82. In FIG. 11 e, the shape is defined by each short-side edges 78 and 80 having two portions 83 a and 83 b converging into a notch 84.

Each of the shapes shown in FIGS. 11 c and 11 d include two protrusions 86. Each protrusion 86 extends from a location L (that joins one long-side edge 74, 76 and one short-side edge 78, 80) towards the other long-side edge 74, 76. Additionally, both protrusions 86 illustrated in FIGS. 11 c and 11 d are substantially parallel to each other. Different numbers and shapes of protrusions may be used on other embodiments. The shapes shown in FIGS. 11 a-e may also include toothed portions 72, such as those illustrated in FIG. 10. For example, some embodiments can include toothed portions 72 near and/or on the portions of the shapes where the long-side portions 74, 76 meet the short-side portions 78, 80.

FIGS. 12 and 13 illustrate the tub 10 including a rectangularly-shaped recess 88. The recess 88 includes a substantially flat surface 90 that is generally parallel to the top 22. The flat surface 90 includes a partial perforation 91 and alternatively a centrally located protrusion 92, shown in FIG. 12. However, in other embodiments the protrusion 92 is located in other positions. The partial perforation 91 defines the surface area of a removable tab that is separated from the tub 10, preferably subsequent to the purchase of the tub 10, to provide access to the wipes within the tub 10. The partial perforations 91 are generally defined by the shapes illustrated in FIGS. 11 a-e. For example, the partial perforation 91 of FIG. 12 is defined by the shape shown in FIG. 11 a and the partial perforation 91 of FIG. 13 is defined by the shape shown in FIG. 11 e. As indicated above, other shapes are possible. The protrusion 92 coupled to or molded with the flat surface 90 facilitates the removal of the removable tab defined by the partial perforation 91. In the embodiment shown, the “partial perforation” is the result of a manufacturing process that to cuts, engraves, partially severs, etches, carves, crops, or partially perforates the flat surface 90 of the tub 10 allowing for relatively easy removal of the removable tab defined by the partial perforation 91 while maintaining the tub 10 substantially sealed prior to the removal of the tab. This process would allow the use of inert gasses to further improve the storage of wipes or paper towels within the tub 10, for example.

FIGS. 14 and 15 illustrate the opening 32 being sealed with another closure defined by a molded cap or fitment 96 placed in the recess 88. The fitment 96 has a lid 98, an attachment portion 100, a hinge portion 102, and a locking portion 104. The hinge portion 102 includes a flexible plate 106 coupling the lid 98 to the attachment portion 100, and a spring 108. The locking portion 104 includes a locking tab 110 coupled to the lid 98, and a release button 112. When depressed, the release button 112 disengages the locking tab 110 and the spring 108 causes the lid 98 to “pop up” from a closed position (FIG. 14) to an open position (FIG. 15). In the closed position and in the embodiments shown, the fitment 96 hermetically seals the tub 10. However, in other embodiments the fitment 96 has a vent (not shown) so that the fitment 96 provides a vented seal. In the embodiment shown, the lid 98 is designed to be manually closed by a consumer single handedly. The attachment portion 100 of the fitment 96 may be press fit or snap fit within the recess 88, or adhered within the recess 88 using an adhesive. Alternatively, the fitment 96 may be configured to be mounted in a recess 26 (FIG. 1), which is defined by an oval-like shape.

As noted above, the flange 28 and opening 32 are located below the plane P. In addition, the closure described above is preferably configured such that when closed, the lid 98 is positioned above the flange 28 (for example, substantially parallel with the top 22) leaving a gap G (shown in FIG. 15) between the lid 98 in which at least part of the next wipe (such as a wipe 116) in a stack of wipes may be positioned. Thus, sufficient room is provided so that wipes 116 may be folded in a manner where the removal of one wipe 116 from the tub 10 through the opening 32 is accomplished such that part of the next wipe 116 is pulled up from the opening 32 and stored between the flange 28 and the lid 98 in a position where it is readily grasped by a consumer (FIG. 15).

FIGS. 16 and 17 illustrate the tub 10 including two foot portions or protrusions 120 extending from the relatively smaller side 16 (FIG. 16) and two foot portions or protrusions 120 extending from the relatively larger side 18 (FIG. 17). Each protrusion 120 is integrally molded with the tub 10 and extends perpendicularly from one side 12, 14, 16, 18. Each protrusion 120 includes a flat surface 122 that allows the tub 10 to sit on a display area supported by the protrusions 120. In other embodiments the protrusions 120 define an arcuate surface. The number, shape, and location of protrusions 120 may vary based on factors such as the projected display area or whether the tub 10 is manufactured to resemble a shape related to the product supported within the tub 10.

As also noted above, in one exemplary construction, the tub 10 includes an open bottom or opening 44. As a consequence, the tub 10 may be filled from the bottom (i.e., the tub may be bottom filled). This and other features of the tub 10 allow for a unique process of filling the tub 10 with wipes during manufacturing. The process of manufacturing begins with thermo-forming the tub 10. Next, the non-woven or other material to be used for the wipes is processed an initial converting stage. This initial converting stage can involve a process whereby the wipe material is wetted with a cleanser, lotion, or similar liquid; folded; and cut. Alternatively, the material may be folded, cut, and then wetted. Of course, dry wipes could also be placed in the tub. When such wipes are packaged the wetting step is eliminated. Once the wipes have undergone an initial converting stage, they are stacked. Stacks consisting of a predetermined number of wipes (for example, 60, 100, 200, etc.) are then loaded into the tub 10. The backing 52 (FIG. 6) is then applied to the tub 10. The tub 10 is then inverted and a closure is applied to the top 22 (label seal 60) or inserted in the recess 26 (fitment 96) to cover the recess 26. Optionally, the steps in the above process can be reordered. For example, it is possible that a closure can be inserted in the recess 26 or applied to the top 22 to cover the recess 26 earlier in the overall process.

FIGS. 18 and 19 illustrate the tub 10 and a support or holder 125 suitable for supporting the tub 10. The holder 125 includes a substantially flat panel 128, two opposite rails 130, and a hanging tab 132 extending from the panel 128. The holder 125 is configured to engage the tub 10 such that portions of the flange 48, corresponding to the sides 14, 18, are supported by the rails 130 of the holder 125 (FIG. 19). Alternatively, the holder 125 can be configured to engage the tub 10 such that portions of the flange 48, corresponding to the sides 12, 16, are supported by the rails 130. The holder 125 can include a stop (not shown) extending from the panel 128, opposite to the hanging tab 132, to help support the tub 10 in the illustrated position (FIG. 19). The holder 125 allows the tub 10 to be placed at various display locations by mounting the holder 125 at such locations. With that purpose, the holder 125 can be suspended at a display rack (not shown) by the tab 132, for example. The holder 125 can also include attachment mechanisms such as Velcro®, double-sided tape, or similar products coupled to the panel 128 opposite to the tub supporting side. Additionally, the holder 125 can be manufactured of plastic materials or metal-based material including magnetic properties for attachment of the holder 125 to metal racks, doors, and display areas.

Various features and advantages of the invention are set forth in the following claims. 

1. A container for wipes including: a tub of thermoformed material, the tub comprising at least one side wall and a top integrally formed with the side wall; a recess centrally located with respect to the top; a first flange defined by the recess and including a first opening, the first flange being substantially parallel to the top; a second opening opposite to the first opening and defined by a periphery of the at least one side wall; and a second flange extending from the periphery of the at least one side wall.
 2. The container of claim 1, wherein the first flange is placed between the top and the second flange.
 3. The container of claim 1, further comprising a backing substantially adjacent to the second opening and coupled to the second flange.
 4. The container of claim 3, wherein the backing includes a flap extending away from the tub, the flap operable to support the weight of the container.
 5. The container of claim 1, further comprising a closure with a first portion and a second portion, the first portion permanently coupled to the tub.
 6. The container of claim 5, wherein the closure is coupled to the top of the tub such that the second portion at least partially seals the first opening.
 7. The container of claim 5, wherein the closure is substantially parallel to the first flange.
 8. The container of claim 1, further comprising a closure with a first portion and a second portion, the first portion fitted at least partially within the recess of the tub.
 9. The container of claim 8, the closure further comprising a spring actuating the second portion from a close position to an open position with respect to the first portion, such that in the close position the second portion at least partially seals the first opening.
 10. The container of claim 1, wherein the first flange includes an edge defined by at least one smooth edge portion and at least one toothed edge portion.
 11. The container of claim 1, further comprising a support including at least one rail, the support operable to engage the second flange of the tub with the at least one rail.
 12. A container operable to support wetted tissue material, the container comprising: a tub formed of thermoformed material, the tub including at least one side wall and a top integral to the at least one side wall; a recess extending from the top; a first flange defined by the recess and including a first opening; and a periphery defining the first opening, the periphery including at least one substantially smooth edge portion and at least one toothed edge portion.
 13. The container of claim 12, further comprising a second flange extending from the at least one side wall, the second flange being opposite with respect to the top.
 14. The container of claim 13, further comprising a coupling portion including a rail operable to receive at least a portion of the container, the coupling portion operable to slide with respect to the tub to a mounted position and engage the second flange of the tub with the rail.
 15. The container of claim 13, further comprising a backing substantially coupled to the second flange.
 16. The container of claim 12, further comprising a closure with a first portion and a second portion, the first portion permanently coupled to the tub and the second portion operable to pivot with respect to the first portion.
 17. The container for claim 12, further comprising at least one protrusion extending from the at least one side wall, the at least one protrusion operable to support the container on a substantially upright position.
 18. A method for forming a container to support a number of wipes, the method comprising: thermoforming a one-piece tub including at least one side wall, a top integral with the at least one side wall, a recess extending from the top, and a substantially flat surface defined within the recess; and forming a contour for a first opening on the substantially flat surface, forming the contour includes defining at least one edge of a first flange, forming at least one substantially smooth cut portion, and forming at least one toothed cut portion.
 19. The method of claim 18, further comprising coupling a closure to the top to at least partially cover the recess.
 20. The method of claim 18, wherein thermoforming the tub includes forming a second flange opposite to the top and extending outwardly from the at least one side wall.
 21. The method of claim 20, further comprising coupling a backing to the second flange. 